Electric switches and mountings therefor



Feb. 9, 1960 J. H. SCHMIDT 2,924,681

ELECTRIC SWITCHES AND MOUNTINGS THEREFOR Filed Jan. 16, 1958 2Sheets-Sheet 1 7 l. 3 7 19 l a. i T; ,1 7:) ii

21/ i0 t m J6 .llli 7* i9 2 22 a 14 '3 s1 1 15 H INVENTOR. $4505 Hfimwmr Feb. 9, 1960 Filed Jan. 16, 1958 J- H. SCHMIDT ELECTRIC SWITCHESAND MOUNTINGS THEREFOR 2 Sheets-Sheet 2 53 n INVENTOR.

lever. :ations also disclosed, includes the aforesaid basic con-ELECTRIC SWITCHES AND MOUNTINGS THEREFOR Jacob H. Schmidt, Aurora, Ill.

Application January 16,1958, Serial No. 709,260 3 Claims. (Cl. 20067)The present invention relates to improvements in electric switches andmountings therefor, and is more particularly concerned with the novelconstruction and parts arrangement of a toggle type electric switch,which may be easily and inexpensively assembled with but slightmodification to provide an on-ofi switch or a three-way switch, and to anovel plate assembly for the selective mounting of one or more suchswitches and/or outlet receptacles on an outlet box cover plate.

The invention generally, comprises the production of a toggle typeswitch having a novelly constructed body and a novel contact carryingtoggle lever therein and novel means to facilitate snap action of saidlever so as to open and close a circuit or circuits in which the switchis connected. The structure is such that, with the substitution of butfew minor parts, it can be converted into either one of. two commonlyused types of switches, thus minimizing manufacturing costs and reducingparts inventory.

In one of the two basically similar embodiments herein disclosed, theswitch elements are enclosed in a hollow body of insulating material.They include a pair of spaced terminal contact structures which areselectively engaged and contacted by a contact structure mounteddirectly on and movable with a toggle type actuating A modificationthereof, involving slight part varitact structure and also a thirdterminal contact structure that is always in electric connectionwith thecontact structure carried by the toggle type actuating lever. The bodiesof these switches have substantially like outside configurations andthey are adapted to be mounted,

either or both of them as well as any other electrical component such asan outlet receptacle of similar external configuration or an apertureclosing blank, on an outlet box cover plate having a multiplicity ofopenings .therein.

It is therefore an object of the invention to provide a novellyconstructed toggle type electric switch.

Another object is to provide a switch having but a .minimum number ofparts and which is therefore inexpensive to manufacture, easy toassemble and less likely to become damaged.

Another object is to provide a rugged on-oif toggle .type of electricswitch having but few parts and which parts are not expensive toproduce, are easily installed by unskilled persons, and verysatisfactory in use.

Another object is to provide a novel mounting frame for attachingelectric switches, outlet receptacles and the 1 which will, appear asthe description proceeds, the invention consists of certain novelfeatures of construction,

Patented Feb. 9, 1960 ice - particularly pointed out in the appendedclaims, it being understood that various changes in form, proportion,size and minor details of the structure may be made without departingfrom the spirit of the invention.

Referring to the drawings in which the same characters of reference areemployedto identify corresponding parts:

Figure 1 is a perspective view of an outlet box cover plate havingelectric components mounted therein.

Figure 2 is a back elevational view of the Figure 1 assembly.

Figure 3 is a vertical central sectional view taken on line 3--3 ofFigure 2, but showing the components mounted thereon, in elevation.

Figure 4 is a horizontal sectional view taken substantially on line 4-4of Figure 2, showing an electric switch in elevation.

Figure 5 is an enlarged longitudinal sectional view of an on-off switchembodying features of the present invention, showing parts in elevation.

Figure 6 is a vertical sectional view taken substantially on line6-6 ofFigure 5.

Figure 7 is a fragmentary side elevational view of the switch housing.

Figure 8 is a detail perspective view of a bail.

Figure 9 is a fragmentary perspective view of the toggle lever.

Figure 10 is an enlarged longitudinal sectional view of a three-wayswitch embodying features of the present invention and showing parts inelevation.

Referring to the accompanying drawings and particularly to the assemblybest shown in Figures 1 to 4, an improved type of switch generallyindicated at 10, is removably mounted on the back face of an outlet boxcover plate 11 by means of a novel frame 12. In the present disclosure,which is for purposes of illustration and not limitation, the coverplate 11 has a plurality (in this instance three) substantiallyrectangular openings 13 in one of which the switch 10 is mounted.Another one of the openings 13 may be closed by a blank 14,

' while the third opening can mount anoutlet receptacle 15. The outletreceptacle is interiorly of conventional construction, however its bodyis interchangeable with the body of the switch disclosed herein. As willbecome better understood as the description proceeds, the assembly caninclude any selected combination of switches, blanks or outletreceptacles, which are readily interchangeable one with the other andare held in place by the novel frame 12.

The frame 12 comprises a sheet metal stamping formed substantiallyrectangular and smaller than the dimensions of the cover plate 11, andit is provided with reinforcing flanges on its edges and is formed onits ends with planularly ofiset apertured wings 16 disposed inregistering alignment with the conventional holes provided in the coverplate 11 for receiving screws 17 to mount the assembly on an outlet box.The frame, in this instance, has three substantially rectangularopenings 18 corresponding to the cover plate openings 13, each toreceive either a switch 10, a blank 14, or an outlet receptacle 15. Asis perhaps best illustrated in Figures 4, 5 and 7, the switch 10, aswell as the blank and outlet receptacle, has end flanges 19 providing'reverse shoulders 21 against which are abutted the margins of the plateat the ends of the respective opening 18 through which the switch bodyprojects. With the switch, and/or outlet receptacle and blank, somounted with respect to the frame, the sub-assembly is .placed againstthe back face of'the cover plate 11 and the whole is secured thereto asby screws 22. These screws are of a length to locate their heads forready accessand they preferably are fitted with spacer sleeves 2 2a.AcceSsto the switch and outlet receptacle is obtained through the coverplate openings 13 in registering alignment therewith. It should be quiteevident that. the installation and inter'chan ge ofs'witches,'bl'anks-ai1d outlet r'eceptacle's can'be' easily and quicklyeifecte'd and requires no special skills. I, v I

The electric s'witch'ltl, 'best illustrated Figure 5, is anon-off toggletyp'e' switch. It comprises a cubical body 23 of insulation inaterialrecessed from one face to provide parallel side walls '24, end walls".25 and 26 and a bottom wall '27. fMount'ed firmly within the body atenema of the recess and preferably to the inside face of the end wall.25 is acontact structure 28 having an inturned terminal flange 29 onits upper extremity. The ,contact structure may be secured in place inany approved manner and it has, threaded therein, a wire connectorscrew'31 extending to the outside of the body. A contact structure 32 ismounted at the other end of the recess, preferably on the inside face ofthe end wall 26. This contact structure is formed substantially mid-'way between its ends with a pair of laterally spaced spring terminalfingers 33. A wire connectorscrew 34- is threaded into this contactstructure and extends to the .outside of the body for ready access.

' The switch also includes a cover or closure plate 35 which overliesthe recess and has a central rectangular aperture therein through whichthe finger engaging portion or lever 36 of a toggle element 37 extends.The toggle element is best shown in Figures 6 and 9, and it comprises asubstantially T-formation of insulation material, usually plastic,including the said lever 36 and an elongated body or head 38. 'Adie-electric insulator 39 is integrally mounted on the elongated bottomface of the head 38 and an electric conductor strip or wear plate v41 issecured to the bottom face of said toggle lever. The strip 41 has a pairof longitudinally spaced perpendicular shoulders 42 formed integraltherewith, or attached thereto as by means of its mounting screws 43,and the portion of the strip between'said shoulders is formed with adownwardly facing longitudinal channel or groove 44 all for purposes tobe described presently. The strip 41 is longer than the length of thehead 38 to which it is attached so as to provide end contact terminals45 and 46.

The toggle element 37 also is formed on each side face with bearingtrunnions 47 which are adapted to be seated in the complemental bearings48 formed on the side walls of the body 23 and in the closure plate 35.It will be apparent that the toggle element is mounted in thebody-closure plate assembly in such manner thatit may be oscillatablyrocked on its trunnions into switch open and switch closed positions, asshown in full and dotted lines in Figure 5.

In" order to insure snap action operation of the toggle element 37 so asto prevent arcing, a novel toggle spring assembly is operably connectedwith the toggle element. This assembly comprises a pin 51 having a head52 that is seated in the channel 44 in the contact strip 41 and overwhich is mounted a normally tensioned coil spring 53 having its upperend bearing against the head 52 and its lower end bearing against ametal bearing element 54 telescoped loosely on the lower end of saidpin. The bearing element is seated at all times in a lateral recess 55formed in the bottom wall 27. The toggle spring assembly functions atall times to retain the toggle element in on and off position. When inon7 position, the contact terminal 45 of the strip 41 is held inelectrical contact with the terminal flange 29 and the other contactterminal 46 is held in engagement between the spring terminal fingers33.

g In order to facilitate assembly of the toggle structure, the pin 51 isfurnished longer than required was to extend through an aperture 56, inthe bottom wall 27, *asindicated in dot-dash lines in Figure 5, so as toenable the spring-pin subassembly to be held while the toggle elementand closure plate are being assembled on' the body. After assembly, theextended pin portion is broken off; a score line 57 preferably beingformed on the pin to facilitate such separation.

Complete assembly of the switch is made simple by providing novel meanson thebody 23 that is easily and quickly engaged over the closure plate35 to retain the mechanism inplace so as to facilitate transit handling.This means comprises a -pair-of bails 58 (Figure 8) formed fromspring-wire stocksubstantially U-shaped and arranged one adjacent eachend of the body. The free ends-of the U-shaped bail are turned inwardly,as at 59, and are engaged normally 'inapertures 61 in the body sidewalls24. These bails lie in grooves 61a and 61b in the body and coverrespectively, so as to lie beneath the surface of the switch body andcover. In order todisengage the bails from their holding. position overthe closure plates, the engaged ends 59 are lifted out of the engagedapertures and the bail is then slid upwardly sufficiently to permit itto be swung outwardly off of the engaged end of the closure plate.

The three-way switch shown in Figure 10, is substantially like theon-otf switch described hereinabove and like numerals are used toidentify identical parts. This switch has a third terminal connectionprovided in the forum of a contact structure 62 seated on or partiallyembedded in thebody bottom wall 27. structure includesa lateral recess63 in which the bear- The contact ing element 5'4 on the end of thetoggle pin5-1 is seated, and a wire connecting screw 64, threaded intosaid contact structurecxtendsto the outside of the bottom 'wall.

The i switch assembly also includes'a contact structure 65 which isinstalled in place'of' the contact structure '32 of the previouslydescribed switch, and which is identical to the contact structure 28.This contact structure 65 has an inturned terminal contact 66 on itsupper end.

The operation of the toggle element 37 is such that when assemble; andare positive in their operation. Furthermore, the novel toggle structurerigidly carries an electric conductor for direct electric engagement"with selected terminal structures when in an extreme position. Thehereindisclosed switch structure is not restricted to multiple switchinstallation, but may be installed singly by using a conventionalsingle-unit strap (not shown). Such mounting is rendered possible byforming each body end flange 19 with a shallow recess or notch 67 thatmay be frictionally engaged by cars on the strap to hold the strap andswitch body together. In such mounting the balls 58 may be omitted. I

It is believed that my invention, its mode of construction and assembly,and many of its advantages should be readily understood from theforegoing without, further description, and it should also be manifestthat while preferred embodiments of the invention have been-shown anddescribed for illustrative purposes, the structural details arenevertheless capable of wide variation within the purview of myinvention as defined in the appended claims.

What I claim and desire to secure by Letters Patent elongated body and alever, the latter extending through the cover for manual engagement, awear plate of electrically conductive material secured to the togglebody member and located entirely within the recess, a guideway in saidwear plate, stops at the ends of said guideway, a pin having a headslidably engaged with the guideway, a bearing element telescoped on theother end of said pin, a contact structure in which said bearing elementis seated, a spring on said pin compressed between the head and bearingelement, said pin, spring and hearing element assembly being effectiveto cause snap action oscillatable movement of the toggle member whensaid lever is manipulated and to maintain an electrical connectionbetween the wear plate and said contact structure, a contact structurein said recess engageable by the wear plate when the toggle member is inone of its extreme positions, and another contact structure in saidrecess engageable by the wear plate when the toggle memher is in itsother extreme position.

2. In an electric switch, a body of insulating material recessed fromone face, a cover for said recess, a toggle member pivotally mounted insaid recess and movable to on and off positions, said member including abody and a lever, said lever extending through the cover for manualengagement, a wear plate of electrically conductive material secured tothe toggle member body and located entirely within the recess, aguideway in said wear plate, stops at the ends of said guideway, a pinhaving a head slidable along said guideway, a bearing element telescopedon the other end of said pin, a contact structure in a wall of therecess in which said bearing element is seated, a spring on said pincompressed between the head and bearing element to maintain anelectrical connection between the said contact element and weareffective to cause snap action oscillatable movement of the togglemember when said member is manipulated, and a stationary contactstructure in said recess which is engageable by the wear plate when thetoggle member is in its on position.

3. In an electric switch, a body of insulating material recessed fromone face and including at least one wall, a cover for said recess, atoggle lever pivotally mounted in said recess and extending through thecover for manual engagement, a wear plate of electrically conductivematerial secured to the toggle lever and located entirely within therecess, electrical terminal contacts on the ends of said wear plate, aguideway in said Wear plate, stops at the ends of said guideway, a pinhaving a head slidably engaged with the guideway, a bearing element onthe other end of said pin, a recess in said one wall in which saidbearing element is seated, a spring on said pin compressed between thehead and bearing element, said pin, spring and bearing element assemblybeing effective to cause snap action oscillatable movement of the togglelever when said lever is manipulated, and a pair of contact structuresin said recess engageable by the terminal contacts on the wear platewhen the toggle lever is in one of its extreme positions.

References Cited in the file of this patent UNITED STATES PATENTS1,023,246 Fountain Apr. 16, 1912 1,351,443 Robertson Aug. 13, 19201,389,713 Thompson Sept. 6, 1920 1,762,787 Nelson June 10, 19301,812,914 Williams July 7, 1931 2,289,863 Batcheler July 14, 19422,623,142 Karl Dec. 23, 1952 FOREIGN PATENTS 183,234 Great Britain July18, 1922

